How USColorworks Scaled On-Demand Production Without Sacrificing Profitability

FOR DECADES, SCREEN PRINTING has been built around efficiency at scale: maximize production runs, minimize downtime, and move inventory. But what happens when your clients no longer want large batches? What happens when they want more variety, smaller orders, faster turnarounds — and less waste?

That’s where print-on-demand (POD) comes in. While once considered a niche reserved for e-commerce startups or direct-to-garment (DTG) printers, today’s version of POD offers something more substantial: The ability to produce only what’s needed, when it’s needed, and without sitting on unsold inventory or guessing what might sell.

And now, thanks to advancements in workflow automation and production software, even high-volume screen printers can take advantage of POD’s flexibility without compromising on profitability.

One shop that’s made this transition successfully is USColorworks, based in Monroe, NC. A decorated apparel and promotional products provider, the shop produces more than 30,000 garments per day — 3,000 to 5,000 of which are on-demand!

Even high-volume screen-printing shops are making the move to print-on-demand.

Expanding Without Footprints

When uscolorworks began looking at ways to enter the on-demand space, they faced a challenge shared by many screen printers: How do you make thousands of tiny orders profitable — especially when each one might need to move through a different process or decoration method?

Without an automated workflow, managing thousands of small, one-off orders alongside bulk production simply was impractical. It risked quality inconsistencies, missed deadlines, and added costs.

The turning point came in 2021 when USColorworks partnered early with the STAHLS’ Fulfill Engine team to co-develop and implement a system built around their exact needs. The platform connected incoming orders to production through automated batching, QR code labeling, and built-in shipping integration — all while standardizing quality control along the way.

“This system allows us to produce an order the same way every time,” says Rodney McDonald, co-founder and co-owner. “If you find and fix a flaw in the process, it’s fixed forever so it doesn’t affect any other orders.”

Why POD Isn’t Just About Single Shirts

One common misconception about POD is that it’s only about printing one item at a time. But as shops like USColorworks have proven, it’s really about eliminating inefficiency and guesswork — regardless of quantity.

It’s also about unlocking new sales opportunities. Today, USColorworks uses the workflow system to support a wide range of on-demand clients, including white-label stores, enterprise partners, Shopify integrations, and even networked decorators. Orders flow in from all over the world and are processed through the platform with a consistent, reliable system that works at scale.

The company now fulfills 25% of its total revenue through on-demand orders. Having a standardized process helps reduces errors, simplifies inventory, and enables delivery in as little as two days.

An integration with everyday production makes the STAHLS’ Fulfill Engine a platform uniquely suited to shops that need flexibility, whether it’s DTG, DTF, embroidery, engraving, UV decals, or bulk screen printing.

Automation Powering Repeatability

Every order at USColorworks is tagged with a QR code that acts like an instruction manual — from decoration details to shipping method. That code flows with the blank through the entire production cycle, eliminating the need for operators to make “tribal knowledge” decisions on the fly.

“Everything about POD has to be a continuous, efficient flow,” says McDonald. “The process needs to be automated and very repeatable. You can’t have operators within the system stopping and making assumptive decisions about orders because you’ll either get it wrong or cost your shop money.”

That same QR system allows USColorworks to process complex multi-item orders with different decoration methods such as a DTF-printed shirt, an embroidered hat, and an engraved tumbler, while still shipping them as a single, unified package.

The USColorworks Team (USCW) is (left to right) Kevin Yerkes, Director of Operations; Tony Mizzi, Owner/Founder: Rodney McDonald, Owner/Founder; and Jacob Wheeler, Digital Manager.

Built by Decorators, for Decorators

This platform was designed not as generic production software, but as a solution developed on real shop floors. As an early adopter and test shop, USColorworks played a key role in shaping how the platform functions in the real world.

“This software was developed in our facility to handle a specific customer doing a lot of high-volume, low-quantity orders,” says McDonald. “Then, as that customer and the software grew, we could handle other POD customers and other decoration methods and processes.”

That deep integration with everyday production makes the platform uniquely suited to shops that need flexibility. Whether it’s DTG, DTF, embroidery, engraving, UV decals, or even bulk screen printing, it all flows through one system.

o produce only what’s needed, when it’s needed, and without sitting on unsold inventory or guessing what might sell.

Making the Case for Change

Mcdonald acknowledges that many decorators hesitate to change how their shop runs — especially if things already are working. But he encourages owners to keep an open mind.

“If you watch the demo and think, ‘Oh, that’s not how my shop runs,’ I’d challenge that,” he says. “Many decorators are comfortable doing things the way they did them yesterday. So, first accept change in your processes if that’s the best way to move forward.”

He adds that the system is highly configurable, meaning shops don’t have to abandon their preferred workflows; they can adapt the system to match how they want to operate.

“We encourage people to visit our facility, and once they see fulfillment in action, they realize how much that process has jumped past them.”

Every order at USColorworks is tagged with a QR code.

What’s Next?

The industry is shifting. Online stores are open year-round. Clients expect faster turnarounds. Inventory is becoming more of a liability than an asset. Print-on-demand allows shops to meet these needs without overextending their teams or physical space.

McDonald sees the writing on the wall: “We’re almost forcing our customers to put smaller orders into Fulfill Engine because there’s just no way we can do them manually and make any money.”

The platform also gives shops access to a vetted decorator network, making it easier to route overflow orders to other trusted printers when needed. That kind of flexibility is something traditional screen print workflows simply can’t deliver on their own.

PHOTO GALLERY (6 IMAGES)

PHOTOS: USCOLORWORKS